arXiv subjects

Chengtao Wen

Publications and source records attributed to Chengtao Wen.

9 recordsLinked to original sources

arXiv2026

Toward Certified Functional Safety for Industrial Humanoid Robots: The Fail-Passive Gap and a Feasibility Study

Industrial humanoid robots are constrained less by locomotion or manipulation capability than by the immaturity of functional safety certification for legged platforms. The root difficulty is that the safe state of a legged robot is an actively-controlled state, which violates the fail-passive assumption underlying ISO~13849-1 / EN~60204-1: removing power from a walking biped causes an uncontrolled fall, so classical de-energization is itself a hazard. We term this the fail-passive gap and use a certified external safety chain (light curtain, emergency stop, fail-safe input, fail-safe PLC, and wireless PROFIsafe) as an instrument to locate it precisely: because the external chain is closed and quantifiable with established methods (PFHD, DC, CCF, PL/SILCL), the residual uncertifiable element is pinpointed to the robot-side reaction chain. Using a Siemens fail-safe S7-1500 emergency-stop reference, we show its certifiable Reaction subsystem is contactor-based power removal (Stop Category~0)---exactly the element a balancing humanoid cannot have. We deliberately do not claim end-to-end certified PL~e / SIL~3. We validate the approach on a Unitree G1 EDU pick-and-place cell in a 3m x 1.5m semi-enclosed workspace, and contribute a humanoid-specific analysis of the active safe state (fall-as-hazard, single-support stop bounds, balancing-policy residual risk, ISO~13855 separation) and a provenance-labeled timing budget. Hosting an industrial software-defined automation (SDA) controller on the robot, co-located with the balancing policy, moves robot-side PROFINET/PROFIsafe reception onto a standardized IEC~61131-3 interface; because the G1's onboard compute is not safety-rated hardware, this endpoint is not a certified safety runtime, which reinforces rather than resolves the fail-passive gap and localizes it to the SDA-to-balancing-policy interface.

cs.RO↗

arXiv2026

A Deployment Case Study in Robotic Apparel Automation: Digital Twin Integration, Interoperability, and Workforce Enablement

Despite steady advances in flexible automation in sectors such as electronics and automotive manufacturing, apparel automation remains challenging because fabrics are deformable and difficult to manipulate with robots. This paper presents a deployment-oriented case study of a robotic sewing system for denim manufacturing, emphasizing the system-level integration required for practical adoption. At the engineering level, a digital thread module parses DXF production drawings into process parameters and executable robot trajectories, reducing manual programming effort and enabling rapid re-targeting across sewing operations. In parallel, a digital twin of the workcell is used during pre-deployment to validate reach and clearance, refine layout and sequencing, evaluate operator access, and assess cycle-time compatibility with upstream and downstream tasks, thereby reducing commissioning risk. At deployment, the system integrates a collaborative robot with conventional sewing equipment, welding, suction fixtures, and machine-level controllers through an interoperability layer. Runtime monitoring and verification, including seam monitoring, collision checking, and trajectory-level validation, improve robustness under environmental variability, while operator-facing training and guidance tools support setup, troubleshooting, and technology adoption. Two staged factory deployments on denim shorts, covering 2D pocket operations and 3D garment-shaping seams, show that digital-twin-based validation, digital-thread-driven task generation, interoperability, runtime verification, and operator training are important for scaling robotic apparel automation.

cs.RO↗

arXiv2025

Robotic Automation in Apparel Manufacturing: A Novel Approach to Fabric Handling and Sewing

Sewing garments using robots has consistently posed a research challenge due to the inherent complexities in fabric manipulation. In this paper, we introduce an intelligent robotic automation system designed to address this issue. By employing a patented technique that temporarily stiffens garments, we eliminate the traditional necessity for fabric modeling. Our methodological approach is rooted in a meticulously designed three-stage pipeline: first, an accurate pose estimation of the cut fabric pieces; second, a procedure to temporarily join fabric pieces; and third, a closed-loop visual servoing technique for the sewing process. Demonstrating versatility across various fabric types, our approach has been successfully validated in practical settings, notably with cotton material at the Bluewater Defense production line and denim material at Levi's research facility. The techniques described in this paper integrate robotic mechanisms with traditional sewing machines, devising a real-time sewing algorithm, and providing hands-on validation through a collaborative robot setup.

cs.RO↗

arXiv2024

Optimizing Multi-Touch Textile and Tactile Skin Sensing Through Circuit Parameter Estimation

Tactile and textile skin technologies have become increasingly important for enhancing human-robot interaction and allowing robots to adapt to different environments. Despite notable advancements, there are ongoing challenges in skin signal processing, particularly in achieving both accuracy and speed in dynamic touch sensing. This paper introduces a new framework that poses the touch sensing problem as an estimation problem of resistive sensory arrays. Utilizing a Regularized Least Squares objective function which estimates the resistance distribution of the skin. We enhance the touch sensing accuracy and mitigate the ghosting effects, where false or misleading touches may be registered. Furthermore, our study presents a streamlined skin design that simplifies manufacturing processes without sacrificing performance. Experimental outcomes substantiate the effectiveness of our method, showing 26.9% improvement in multi-touch force-sensing accuracy for the tactile skin.

cs.RO↗

arXiv2023

Robotic Defect Inspection with Visual and Tactile Perception for Large-scale Components

In manufacturing processes, surface inspection is a key requirement for quality assessment and damage localization. Due to this, automated surface anomaly detection has become a promising area of research in various industrial inspection systems. A particular challenge in industries with large-scale components, like aircraft and heavy machinery, is inspecting large parts with very small defect dimensions. Moreover, these parts can be of curved shapes. To address this challenge, we present a 2-stage multi-modal inspection pipeline with visual and tactile sensing. Our approach combines the best of both visual and tactile sensing by identifying and localizing defects using a global view (vision) and using the localized area for tactile scanning for identifying remaining defects. To benchmark our approach, we propose a novel real-world dataset with multiple metallic defect types per image, collected in the production environments on real aerospace manufacturing parts, as well as online robot experiments in two environments. Our approach is able to identify 85% defects using Stage I and identify 100% defects after Stage II. The dataset is publicly available at https://zenodo.org/record/8327713

cs.RO↗

arXiv2020

Neural Subgraph Matching

Subgraph matching is the problem of determining the presence and location(s) of a given query graph in a large target graph. Despite being an NP-complete problem, the subgraph matching problem is crucial in domains ranging from network science and database systems to biochemistry and cognitive science. However, existing techniques based on combinatorial matching and integer programming cannot handle matching problems with both large target and query graphs. Here we propose NeuroMatch, an accurate, efficient, and robust neural approach to subgraph matching. NeuroMatch decomposes query and target graphs into small subgraphs and embeds them using graph neural networks. Trained to capture geometric constraints corresponding to subgraph relations, NeuroMatch then efficiently performs subgraph matching directly in the embedding space. Experiments demonstrate NeuroMatch is 100x faster than existing combinatorial approaches and 18% more accurate than existing approximate subgraph matching methods.

cs.LG↗

arXiv2020

Contact-Rich Trajectory Generation in Confined Environments Using Iterative Convex Optimization

Applying intelligent robot arms in dynamic uncertain environments (i.e., flexible production lines) remains challenging, which requires efficient algorithms for real time trajectory generation. The motion planning problem for robot trajectory generation is highly nonlinear and nonconvex, which usually comes with collision avoidance constraints, robot kinematics and dynamics constraints, and task constraints (e.g., following a Cartesian trajectory defined on a surface and maintain the contact). The nonlinear and nonconvex planning problem is computationally expensive to solve, which limits the application of robot arms in the real world. In this paper, for redundant robot arm planning problems with complex constraints, we present a motion planning method using iterative convex optimization that can efficiently handle the constraints and generate optimal trajectories in real time. The proposed planner guarantees the satisfaction of the contact-rich task constraints and avoids collision in confined environments. Extensive experiments on trajectory generation for weld grinding are performed to demonstrate the effectiveness of the proposed method and its applicability in advanced robotic manufacturing.

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arXiv2020

LFZip: Lossy compression of multivariate floating-point time series data via improved prediction

Time series data compression is emerging as an important problem with the growth in IoT devices and sensors. Due to the presence of noise in these datasets, lossy compression can often provide significant compression gains without impacting the performance of downstream applications. In this work, we propose an error-bounded lossy compressor, LFZip, for multivariate floating-point time series data that provides guaranteed reconstruction up to user-specified maximum absolute error. The compressor is based on the prediction-quantization-entropy coder framework and benefits from improved prediction using linear models and neural networks. We evaluate the compressor on several time series datasets where it outperforms the existing state-of-the-art error-bounded lossy compressors. The code and data are available at https://github.com/shubhamchandak94/LFZip

eess.SP↗

arXiv2019

Reinforcement Learning on Variable Impedance Controller for High-Precision Robotic Assembly

Precise robotic manipulation skills are desirable in many industrial settings, reinforcement learning (RL) methods hold the promise of acquiring these skills autonomously. In this paper, we explicitly consider incorporating operational space force/torque information into reinforcement learning; this is motivated by humans heuristically mapping perceived forces to control actions, which results in completing high-precision tasks in a fairly easy manner. Our approach combines RL with force/torque information by incorporating a proper operational space force controller; where we also exploit different ablations on processing this information. Moreover, we propose a neural network architecture that generalizes to reasonable variations of the environment. We evaluate our method on the open-source Siemens Robot Learning Challenge, which requires precise and delicate force-controlled behavior to assemble a tight-fit gear wheel set.

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